If you want a relative size, the SMD marked at R20 (222 on it) is approximately 1.5~2 mm in width (measured left to right). When you scale up the board as we see here, you get the relative scale of things.

From what I've seen for embedded devices, this is quite big comparatively, especially considering we are not seeing the whole board yet.

The PCB or whatever it's called is almost the height (width) of the EPS power unit (40mm). The battery is rather small and I'm sure open to options in the future.

After speaking to a few people, the hard part will be to leave the PCB intact and re-house it safely and not mess with the electrical conductivity/signals (I'm obviously no electrical expert). I'm hoping to re-connect the battery seperately and allow the two seperate units to be placed inside a frame.

One thing though, I don't think anyone will be putting one inside a stem...

I would take a look at how electric helicopter / boat / car crowd package their electronics. On helis they use heavy duty heatshrink to protect speed controller electronics and that's it. Not familiar with the others, but I'm sure a search at rcgroups.com and a couple of questions will help.

I wouldn't be too worried about the re-housing. I would suggest to have the case 3D printed. I would use a profile joint between the two sides and use some sealant when putting it togheter. For connectors, source some MIL grade connectors from local Radioshack store.

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